Merchandizable expansible metal foil baking container



Feb. 23, 1960 D. L. WATSON ETAL 2,925,933

MERCHANDIZABLE EXPANSIBLE METAL FOIL BAKING CONTAINER Filed Feb. 2, 1956INVENTOR DIGHTON L. WATSON FOREST K- MICHAELSON BY Bang ATTORNEYMERCHANDIZABLE EXPANSIBLE METAL FOIL BAKING CONTAINER Dighton L. Watsonand Forest K. Michaelson, Minneapolis, Minn.

ApplicationFebruary 2, 1956, Serial No. 562,989

' strains. (or. 220-8) This invention is a continuation in part of ourpatent application, Serial No. 475,764, filed December 16, 1954, andrelates to a modification thereof and improvement thereovcr. Moreparticularly, this disclosure embodies disposable and reuseablemerchandisable expandable metal foil baking and cooking cartons forpackaging relatively fluid doughs, batters and other food stuffs of alike character or fish sticks, meats and the like which are ordinarilycooked in a thin film of fluid grease over the bottom of the warming andcooking container.

As heretofore explained in the above mentioned application and ourcontinuation in part, application Serial No. 563,113, filed February 2,1956, for Expandable Metal Foil Baking Cartons and Method of Productionfiled concurrently herewith, the problem of the expense in packaging andsaving of space is an ever present one, both with the manufacturer andthe Storekeeper. In the arrangements as provided for in the abovementioned applications, relatively fluid doughs and batters may beretained by reason of the expansible part interfitting relationship ofthe inner half carton side with the outer half cartonside and thecompressive force of the contents of the carton thereagainst. However,it is found that very watery dough substances andthe like have atendency to lose liquid material unless properly handled in the kitchen,preparatory to baking or cooking in the carton in its expandedcondition. Accordingly, it is an object of this improvement inexpansible metal foil baking and cooking merchandisable cartons andcontainers to provide the same with innerlocking and inner-engagingedges which permit more of fluid batters and doughs being retained inthe container without loss of moisture when in the expanded condition,as in a kitchen preparatory to baking or cooking the contents thereoftherein.

Another object of this improvement is to provide for the manufacture ofexpansible 'merchandisable baking and cooking containers made from metalfoils and which retain the fluid therein of very moist batters whenpackaged for freezing and subsequently thawed in an expandedbaking orcooking relationship.

It is another object of this improvement to provide an expansiblemerchandisable cooking container made from metal foils which in anexpanded relationship retain a layer'and coating of cooking grease atthe bottom thereof without loss through leakage therefrom during cookingor baking.

Further objects and advantages will be apparent from the followingdescription of the accompanying drawings,

wherein:

Figure l is a side plan view of the two carton sections showing theprefabrication of the open carton sides prior States H atom shown inFigures 1 and 2 and joined in overlapping relationship.

Figure Sis a view taken on line 5-5 of Figure 4.

In the following description like parts in the respective figures willbe similarly indicated.

.As explained in our previous parent application and co-pendingapplication filed herewith, each of the half carton sections are thesame size to eifect a sealing action between the sides and bottomportions in both the unexpanded and expanded positions of the halfcarton sections. r

In order to simplify and expedite the modification and improvement asdisclosed herein, each of the half carton sections A'and B are formedfrom blanks or the cutting of a prefabricated pan into two half cartonsections of the same size and dimensions as described in the abovementioned applications. For example, by cutting a prefabricated aluminumfoil carton, pan or container, of generally rectangular configuration,there is provided the half carton sectionA having a bottom 10, backclosure wall 11, side walls 12 and 13, and an open side as de fined bythe line of cut 15. The other half of the pan, or carton which has beencut, and indicated as section B, is similarly provided with .a bottompanel 20, back wall 2'1, side walls 22 and 23, and an open side which isdefined by the same out line 15, as previously described for the halfcarton section A.

In prefabricating an aluminum foil pan, the open top edge of the pan isusually provided with a rim flange 28, extending entirely thereabout andturned outwardly and downwardly about the circumference of the pan edgeto strengthen and reinforce the foil forming this edge.

In order to change this arrangement and provide for interlocking tonguesand guide grooves, the side rims 28 on the box section B are retained asouter folded flanges 29 and 30 on each wall section 23 and 22,respectively, and as illustrated in Figures 1, 2 and 4. These outerfolded flanges, as an integral portion of wall sections 23 and 22 formtongues which fit into cooperative guide grooves on the other half pansection A, as hereinafter described. The rim 28 on the other half bakingpan and carton section A, is retained in turned back and downrelationship relative to back wall 11 and at the sides, relative to sidewalls 12' and 13, is lifted and turned inwardly and downwardly asflanges 31 and 32 to provide guide grooves for the tongues 29 and 30respectively.

In order to form one innerlocking seal, of the character hereindescribed, which prevents leaking of moisture from very fluid doughs andbatters and ready pulling apart of the half pan and carton sections,each of Figure 4 is a perspective of the half carton sections the walls12, 13 and 22, 23 at their open ends formed by the out line 15, areprefabricated by hand or suitable machines. For example, as illustratedin Figure 2 and Figure 3, the cut line 15 represents a line of cut madeto divide a prefabricated aluminum foil pan or blank forms into half pansections, as described. In the representative examples, illlustrated inthe Figures 1, 2 and 4 there is provided in each of the sides 12, 13 and22, 23, cut lines 34 of one-eighth inch in depth, just below andparallel to the lower edges of the flanges 29, 30 and 31, 32 in the sidewalls 22, 23 and 12, 13, respectively. In the lower portion of walls 22,23 and 12, 13, and in spaced relationship to the cut lines 34, there isprovided angular cut lines 35 extending inwardly of the walls for adepth of one-eighth inch. The cut lines in each of the walls, asdescribed, are relatively exactly alike and in similar matchingrelationship, and therefore similarly indicated to provide like pairs ofinwardly folding flanges 38 or 39 on walls 12 and 13, respectively, andoutwardly folding flanges 40 and 41, on walls 22 and 23, respectively.

' In the modification illustrated in Figure 3 showing only partialsections of sides 12 and 23, the cut lines 34 for each of the wallsections 12, 13 and 22, 23 are fabricated in the manner as hereindescribed and the cut lines 43 are relatively and correspondingly alikeand extend in parallel relationship thereto, to the same depth and onanangle perpendicular to thecut line 15. In this respect the 'cut' lines43 differ from the angular cut lines 35 and produce, with cut lines 34,straight upper and lower edges shown in Figure'4, these flange elementsare in opposed relationship and adapted to engage in innerlockingengagement. The flanges 38 and 41' interlock in the same manner as theflanges 39' and 40. As illustrated,

the wall 22 with its outwardly and rearwardly turned flange 40 and wall13 with its inwardly and rearwardly turned flange 39, engage inoverlapping and interlocking relationship when the baking pan or cartonsections A and B are in expanded position as representatively villustrated in Figure 5.

Each of the sides 12,13 and 22, 23 of the carton sections A and B,respectively, whencut along the similar cut lines 34 and similar angularcut lines 35, to provide the reversely turned back flanges 38 and 41,have remaining, forwardly projecting wall portions extending in spacedrelationship. That is the cut 34, made in each of the walls 12 and 13,provides upper integral corner extensions 45 and 46, which withoverturned flanges 32 and 31, respectively, provide reinforcingextensions of the guide grooves formed therebetween. The portions of theside walls beneath the angularly cut linesv3-5, as described, providethe extensions 48 and 49 of box .section A with inclined upper edges 50and 51, respectively. The portions of the side walls adjoining theinclined edges 50 and 51 are pressed inwardly from the planes of thewalls 12 and 13, respectively, to extend 'a distance inwardly therefromslightly greater than the edges of the turned in flanges 38 and 39. Thisinward pressing also bends or pushes the vertical edge and body portionsof the extensions 48 and 49, substantially throughout their lengthsgradually inwardly in an upward direction from the points of theirintegral connection with the partial container side walls 12 and 13 andconnecting base 10.

Likewise, in a reverse relationship, the extensions 54 and .55, of pansection B, which are beneath the cut lines 35, as described, are pressedoutwardly to form angular portions 56 and 57 which extend from the walls22 and 23, respectively, a distance slightly more than the distancebetween the walls and the edges of the turned out flanges 40 and 41.This outward pressing also bends or pushes the vertical edge and bodyportions of the extensions 54 and 55 substantially throughout theirlength gradually outwardly in an upwardly extending directionsubstantially throughout their vertical heights. Thus, the extensions54and 55' are bent outwardly, and the extensions 43 and 49 are bentinwardly, as illustrated in Figure 5.

As shown in Figure 4 in conjunction with Figure 5, the end of the foilpansection A,,with its inwardly turned flanges 38 and 39, is telescopedover foil pan section B with its outwardly turned flanges 41 and 40sliding against the inner surface of pan section A. Flanges 29 and 30 ofpan section B slip into the guide grooves formed by flanges 31 and 32and the extended ends 45 and 46, and ride in overlapping andreinforcing-relationship relative tothe section A for a distance ofabout three-eighths inch when the cuts34 and 35, as described, are aboutone-eighth inch in depth. With pan sections A and B fitted together thelower extensions 48, 49 and 54, 55, press in relatively fluid tightrelationship against the side walls of the opposite section.

In Figure is illustrated the manner in which the bottoms and with sidewalls 13, 22 and 12, 23, are engaged in a fluid tight relationship. Asillustratively shown, the bent in end and edge5 1 of extension 49, onthe outer wall 13, presses inwardly against the outer surface of Wall 22and the outwardly bent edge 56 and body portion of extension 54-, on theinner wall 22, presses outwardly against the inner surface of wall 13.The opposite side extensions 48 and 57 of the telescoping pan sides (notshown in detail) likewise engage against the relative walls 23 and 12,respectively.

With lower ends of the inwardly turned flanges 38 and 39, and outwardlyturned flanges 40 and 41 cut on an angle by cut lines 35, as described,the bends in extensions 48, 49 and 54, 55, respectively, provide sinuouspaths which cooperate with the interlocking flanges 38, 41 and 39, 40,respectively, to retain very'fluid battersv and doughs in the pansections in telescoped and expanded relationship. Each pan section beingof the same relative size aflo rds a tight interfitting relationshipwhich aids in the fluid tight juncture of the pan sections, as

described. With the flanges .48, 49; and 54, 55, extending at a verticalheighth of three-eighths inch and a top guide and bottom overlap ofthree-eighths inch the pan in expanded stationary position on a levelsurface will hold water at a depth of 'three-eighths inch. Fluid battersand dough materials which fill the expanded pan do not run out or escapethe overlapping ends.

The provision of the cuts 34 and 35 to provide inturned and outturnedflangedepths of one-eighth inch, as described, to produce athree-eighths inch overlap is the preferred embodiment for general doughand batter usage. However, when relatively light or relatively heavysubstances are tobe packaged the overlap of the guides, pan sides andbottoms .may vary from three thirty seconds to three fourths inches byforming the inturned and outturned interlocking flanges with a depth offrom one thirty second to one-quarter inch. This depth is measuredprimarily by the relative depth of the cuts 34, 35 and 43, as described.

With regard to the modification shown in Figure 3, the cut 43 is made ineach of the side Walls 12 and 23', on a plane parallel to the cut 34' asdescribed, which provides straight end edges for the inturned flange 38'and the outturned flanges 41'. The straight ends on the flanges 38 and41' are satisfactory for many purposes. However, with the more fluid andliquid batters and doughs the inclined angular cuts providing sinuouspaths between the overlapping flanges, extensions and sidewalls arepreferred. The angular lower ends of the flanges 38 and 41 provide avery slight spacing fromthe adjacent cooperative outside wall whichalfords a temperature differential between a cold frozen liquid orbatter and the heated side walls to effect a baking operation andpositively seal any open spaces between the overlaps.

Upon folding back the flanges 38' and 41, as described, the flanges 29'and 31 with corresponding integral wall portions form the extendedtongue 60 and guide groove 61, which engage in the interlockingrelationship of the half carton sections, in the manner as described.The cut lines 43 provide walls 12 and 23' with upright extensions 63and.64 as integral portions of side walls 12 and 23'. The upper cornerportion 65 of extension 63 is kinked or bent in along a relative fold orcurved line 66 to extend substantially flush or inwardly a slightlygreater distance than the inner edge of flange 38. The upper cornerportion 67 of extension 64 is pressed or 'kinked outwardly along foldline 68 to extend substantially flush or outwardly a slightly greaterdistance than the outer edge of flange 41. Thus when the carton sectionsA and B are joined in the manner as illustrated :and described withreference to Figures 4 and 5, each of the relative side flanges, tongueand guide grooves and upright extensions are in an interfittingrelationship. For example, on one side, the wall 23' will telescopewithin wall 12' with the tongue formed by flange 29' and wall 23 slidingwithin the guide groove formed by flange 31' and wall 12', pressed incorner portion and vertical edge of extension 63 engages the outersurface of wall 23', and pressed out corner portions 67 and verticaledge of extensions 64 engages the inner surface of wall 12. The oppositeside walls (not shown) being similar will be joined in a correspondingand relative relationship in the manner as illustrated with reference toFigure 4.

As heretofore indicated the vertical height of extensions 48, 49 and 54,55 may be varied as may the height of the type extension 63 and 64.Likewise the depth of the cuts 34, 35 and 43 may be varied to change theoverlap of the telescoping pan sides and bottom from three-thirtyseconds to about three-fourths inch or more, if desired. However fromthe standpoint of allowing for utilizing the greatest amount of thespace saving value the overlap is preferably not greater thanthree-fourths inch. By raising the height of the extension as 48, 49 and54, 55 in the illustrative example, to one-half inch and placing theexpanded pan on a level surface it will hold up to onehalf inch ofliquid without leakage. However, for practical application, in handlingand manipulating a pan containing very fluid and liquid batters, athree-eighth inch overlap, as described, with approximately athreeeighth inch vertical height in the lower outwardly and inwardlypressed extensions affords a merchandisable, expansible baking andcooking pan made of dispensable metal foil of a thickness of about .0026inch. Other dispensable metal foil containers of the character hereindescribed, may be utilized when made of foil thicknesses. within thecritical range of .003 inchto .0059 inch if properly prefabricated andassembled relative to the weight and contents of the packaged goods tobe dispensed, expanded and baked, cooked or warmed therein. In the usualpackaging for commercial sale the fluid doughs and batters are frozenand packaged or packaged and immediately frozen in the expansible metalfoil containers herein described.

In accordance with the patent statutes, we have described the principlesof construction and operation of our expansible metal foil containersfor baking and cooking liquid doughs and batters, and while we haveendeavored to set forth the best embodiment thereof, we desire to haveit understood that changes may be made within the scope of the followingclaims without departing from the spirit of our invention.

We claim:

1. An expansible and disposable metal foil container 6 for merchandisingfluid doughs and batters comprising a pair of telescoping half cartonsections formed of metal foil of suflicient thickness to beself-sustaining and yet be flexible, each carton section having a bottomportion, side walls extending upwardly from opposite edges of saidbottom portion, and an end wall connected to said side walls and bottomportion, the other end of each section being open to form an open end,portions of said side walls intermediate the top and bottom edges beingfolded toward the end walls thereof, the folded portions on one sectionbeing folded outwardly to form flanges overlying the outer side wallsurface, the folded portions of the other section being folded inwardlyto provide flanges overlying the inner side wall surface of said othersection, said flanges of each section engaging the side walls of theother section in telescoped relation of said sections, the portions ofsaid side walls above and below said flanges projecting beyond theflanges to provide overlapping guide portions for the telescopedsections, elongated flanges on the upper edges of a first of saidsections folded to provide a channel groove accommodating the upper edgeof the second section, the projecting portions of said side wallsbeneath said first-named flanges on said one section being bentoutwardly into surface contact with the side walls of said othersection.

2. The structure of claim 1 and in which the projecting portions of theside walls beneath said first named flanges on said other section arebent inwardly into surface contact with the side walls of said onesection.

3. The structure of claim 1 and including elongated flanges along theupper edges of the side walls of the second of said sections folded intosurface contact with the side walls to which they are secured andslidable in the channel groove of the first section.

References Cited in the file of this patent UNITED STATES PATENTS709,150 Halls Sept. 16, 1902 876,235 Quackenboss Jan. 7, 1908 1,816,399Rohwedder July 28, 1931 1,858,179 Bay May 10, 1932 2,361,984 WilliamsonNov. 7, 1944 2,556,568 Aikman June 12, 1951 2,627,801 Danziger Feb. 10,1953 2,673,003 Stewart Mar. 23, 1954 2,683,953 Hopkins July 20, 1954FOREIGN PATENTS 842,994 France Mar. 13, 1939

